Battery Enclosures

Battery Enclosure Overview
Magna provides comprehensive battery enclosure production and engineering solutions, offering arange of materials such as steel, aluminum, and lightweight composites, to contribute to thestructural integrity, safety, and protection of high-voltage batteries in the body-in-white.
PurposeValue Proposition• Provide comprehensive solutions for the production andengineering of battery enclosures.

• Industry leader since 2011
• Advanced forming and integration projects
are underway within Magna• Global engineering production footprint

Technical Description

Next Steps / Timeframe• The battery enclosure plays a crucial role in the structural
integrity and safety of the body-in-white.
• Protects high-voltage batteries from damage and water.
• These complex assemblies are designed to meet thespecific requirements of different applications.

• In production

SOP
20XX

Ideation

Discovery

Concept

Disclosure or duplication without consent is prohibited

Development

Series Preparation

In Production

1

Aluminum Capabilities

Aluminum Battery Enclosure
Magna's engineering and manufacturing capabilities for complex aluminum assemblies enable them toprovide comprehensive global support for customer needs in aluminum battery enclosures, deliveringsolutions of the highest quality from concept development to high-volume mass production.
PurposeValue Proposition• Houses high-voltage batteries and contributes to thestructural and safety elements of the vehicle’s frame,
while protecting components from potential impact,
heat and water• 20% lighter than comparable steel designs• Aluminum designs offer light weighting andhigh-scalability to produce different
enclosure sizes for different vehicles on one
production line
• Designed as an assembly of extrusions,
castings, and stampings

Technical Description

Next Steps / Timeframe• Constructed of aluminum extrusions and stampings• Joined using a combination of laser hybrid and cold
metal transfer welding ensuring a leak-tight seal
• Leak-tight requirements were achieved using 9.5
meters of laser hybrid weld, pre-weld machining andwashing, and helium gas testing• In production

SOP
20XXIdeation

Discovery

Concept

Disclosure or duplication without consent is prohibited

Development

Series Preparation

In Production

2

Steel Capabilities

Steel Battery EnclosureWith Magna’s broad expertise in engineering and various steel forming and joiningcapabilities, we offer the complete development and production of steel battery enclosure
solutions.
PurposeValue Proposition• Houses high-voltage batteries and contributes to thestructural and safety elements of the vehicle’s frame,
while protecting components from potential impact,
heat and water• Steel battery enclosures combine the structuraladvantage of higher-grade steel and the lower
material cost compared to aluminum or fiber
reinforced plastic• Large one-piece stampings offer improved leaktightness, are safety-critical, and reduce complexity• Optimized battery space utilization using advanced
forming processes

Technical Description

Next Steps / Timeframe• Joined using various welding techniques all meetinga tolerance of .3 mm or less
• Comprised of 258 components• Vertical support crossbars are held to a tolerance of+/- 0.35 mm, or that of a needle point• In production

SOP
20XX

Ideation

Discovery

Concept

Disclosure or duplication without consent is prohibited

Development

Series Preparation

In Production

3

Seamless DesignOne-Piece Tub Battery Enclosure
Magna has achieved a significant breakthrough by developing a stamping process that creates abattery enclosure with near-rectangular corners and sidewalls, eliminating failure modes and increasing
available space for battery components by at least 6%.
PurposeValue Proposition• Manufacture a battery enclosures with near-rectangularcorners and sidewalls• Eliminate failure modes and increase available space forbattery components, ultimately improving the efficiency
and performance of the battery system• Eliminate complex joining solutions that drive
manufacturing costs and high risks to meet sealing
performance• Increases volume for battery cells by at least 6%• Non-structural steel battery enclosure is 18kg lightervs baseline aluminum structural battery enclosure• Designed within BIW to absorb the crash load energy• Cost effective solution

Technical Description

Next Steps / Timeframe• The battery enclosure in a vehicle refers to a protective
housing or container that is specifically designed to houseand secure the vehicle's battery pack
• Magna’s latest projects focus on near-vertical walls, tightradius corners, and functional integrations of the complete
battery system• Preparing for full-scale series production

SOP
20XX

Ideation

Discovery

Concept

Disclosure or duplication without consent is prohibitedDevelopment

Series Preparation

In Production

4